Compressible mattress package including humidifying agent

ABSTRACT

Compressible mattress assembly packages and processes for packaging a compressible mattress assembly for a bed in a box application generally include the addition of a humidifying agent within the package. The humidifying agent provides moisture within the package, which allows the compressed mattress to effectively recover to its uncompressed state when unpackaged with minimal or no defects.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/284, 223, filed Nov. 30, 2021, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

The present disclosure generally relates to a compressible mattress package for use in a bed in a box application, and more particularly, to a compressible mattress package including the compressed mattress sealed within a plastic protective wrap and a humidifying agent therein.

Standalone mattresses are relatively bulky and heavy making it difficult for the customer to purchase, take home a mattress, and maneuver the mattress to its desired location. Oftentimes, at least two people are needed to lift and maneuver the mattress from the retail store to the desired location. Moreover, with respect to delivery, added costs and the associated difficulty in scheduling a mutually agreeable delivery time can serve as an impediment to a sale. It is, however, now known to compress a mattress and to provide the mattress to the customer in a compressed state in a box at the retail store. These mattresses are often referred to as a bed-in-a-box.

When a mattress is compressed and roll packed into a plastic protective wrap, the mattress may not fully recover to its original shape and size when removed from the plastic protective wrap. This may include edge defects, not rising to the original or uniform height. To solve this issue, the foams used to make the compressible mattresses are manufactured at higher densities. This, however, increases the cost of raw materials for the bedding manufacturer.

BRIEF SUMMARY

Disclosed herein are compressible mattress packages for bed in a box applications. In one or more embodiments, the compressible mattress package for a bed in a box application includes a compressed mattress assembly; a humidifying agent; and a hermetically sealed protective wrap about the compressed mattress assembly and the humidifying agent, wherein the compressed mattress assembly has a first height when compressed and a second height when decompressed, wherein the second height is greater than the first height.

In one or more embodiments, a process for packaging a compressible mattress assembly for a bed in a box application includes inserting an uncompressed compressible mattress assembly into an opening of a protective plastic wrap; compressing the compressible mattress assembly and evacuating excess air within the plastic protective wrap; introducing a humidifying agent with the compressible mattress assembly prior to inserting the uncompressed compressible mattress assembly or prior to compressing the compressible mattress assembly; and hermtically sealing the opening in the protective plastic wrap to provide a compressed mattress assembly package.

The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the figures wherein the like elements are numbered alike:

FIG. 1 illustrates a cross section of a compressible mattress assembly consisting of first and second polymeric foam layers in accordance with one or more embodiments of the present invention; and

FIG. 2 illustrates a cross section of a compressible mattress assembly including a pocketed microcoil array intermediate first and second polymeric foam layers in accordance with one or more embodiments of the present invention.

DETAILED DESCRIPTION

Disclosed herein are compressible mattress packages for bed in a box applications. As will be discussed in greater detail below, the compressible mattress assemblies utilized in the packages for bed in a box application are not intended to be limited to any construction. Compressible mattress assemblies for bed in the box applications generally include one or more layers of foam, microcoil arrays, siderails, and the like enclosed within a fabric layer, e.g., an upholstery layer or quilt layer. The compressible mattress assemblies are configured to be roll compressed within a plastic protective wrap, e.g., bag, for subsequent insertion into a box. In the present disclosure, the compressible mattress assembly package includes a humidifying agent within the packaged compressible mattress.

For the purposes of the description hereinafter, the terms “upper”, “lower”, “top”, “bottom”, “left,” and “right,” and derivatives thereof shall relate to the described structures, as they are oriented in the drawing figures. The same numbers in the various figures can refer to the same structural component or part thereof. Additionally, the articles “a” and “an” preceding an element or component are intended to be nonrestrictive regarding the number of instances (i.e. occurrences) of the element or component. Therefore, “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

Spatially relative terms, e.g., “beneath,” “below,” “lower,” “above,” “upper,” and the like, can be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures.

The following definitions and abbreviations are to be used for the interpretation of the claims and the specification. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains” or “containing,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a composition, a mixture, process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus.

As used herein, the term “about” modifying the quantity of an ingredient, component, or reactant of the invention employed refers to variation in the numerical quantity that can occur, for example, through typical measuring and liquid handling procedures used for making concentrates or solutions. Furthermore, variation can occur from inadvertent error in measuring procedures, differences in the manufacture, source, or purity of the ingredients employed to make the compositions or carry out the methods, and the like.

It will also be understood that when an element, such as a layer, region, or substrate is referred to as being “on” or “over” another element, it can be directly on the other element or intervening elements can also be present. In contrast, when an element is referred to as being “directly on” or “directly over” another element, there are no intervening elements present, and the element is in contact with another element.

Referring now to FIG. 1 , an exemplary packaging process 100 for assembling a compressible mattress for a bed in the box application generally includes step 110, which includes inserting an uncompressed compressible mattress assembly into an opening of a protective plastic wrap. The protective plastic wrap, e.g., bag, is generally dimensioned slightly larger than the uncompressed compressible mattress assembly to accommodate the dimensions of the uncompressed compressible mattress assembly and can include a single opening configured to receive the uncompressed compressible mattress assembly. In one or more embodiments, the protective plastic wrap includes two sheets of plastic that underlie and overlie the uncompressed compressible mattress assembly, which can be peripherally sealed upon compression of the uncompressed compressible mattress assembly such as by ultrasonic welding.

In step 120, the uncompressed compressible mattress assembly is compressed such as by a platen. Compression results in evacuation of air within the plastic protective wrap or evacuation of air between the sheets in the event the plastic wrap is not peripherally sealed about any portion of the compressible mattress assembly.

In step 130, a humidifying agent is introduced into the packaging. It should be apparent that the humidifying agent can be introduced prior to or during step 110 or during or subsequent to step 120. The humidifying agent is configured and/or introduced such that the integrity of the humidifying agent is maintained whether that be prior to or subsequent to compression of the uncompressed compressible mattress assembly.

In step 140, the process includes hermetically sealing the opening or any opening of the plastic protective wrap to provide a hermetically sealed compressed mattress assembly package, which includes within the protective plastic wrap the humidifying agent.

In step 150, the process includes folding the compressed mattress assembly package in half, which is typically folded along a longitudinal length dimension of the mattress assembly to minimize box width. However, it should be apparent that the compressed mattress assembly can be folded along the width dimension of the compressed mattress assembly package.

In step 160, the folded compressible mattress assembly package is rolled to form a rolled mattress package that is then inserted into the box as indicated in step 170 to provide a bed in a box suitable for shipping to consumers.

The humidifying agent generally provides a source of moisture within the protective plastic wrap. The humidifying agent can be contained within a moisture permeable package, infused within a substrate such as a paper, foam, sponge, fiber material, and/or sprayed within the plastic protective plastic wrap. By way of example, the humidifying agent can be a water infused paper product, water infused sponge, water infused fiber material, or the like. Suitable humidifying agents are not intended to be limited and can include any humidifying agent material that does not react with the packaging materials or the materials used to form the compressible mattress assembly. Additional substances can be included with the humidifying agent to control the rate of moisture release.

The compressible mattress assemblies may be of any size, including standard sizes such as a twin, queen, oversized queen, king, or California king sized mattress, as well as custom or non-standard sizes constructed to accommodate a particular user or a particular room. By way if example, the compressible mattress assemblies could be a smaller mattress designed for a child or baby Such a mattress may be part of a crib or cradle. The compressible mattress assemblies are generally configured as two sided. In one or more embodiments, the compressible mattress assemblies in accordance with the present disclosure have an overall thickness of about 6 inches to about 14 inches.

Referring now to FIG. 2 , there is depicted a cross sectional view of an exemplary two-sided compressible mattress assembly 200 in an uncompressed configuration in accordance with one or more embodiments of the present invention. The exemplary compressible mattress assembly is not intended to be limited and can include more or less compressible layers with different properties, different materials, compressible side rails, and the like.

The exemplary mattress assembly 200 as shown includes a first polymeric foam layer 202 and a second polymeric foam layer 204. The compressible mattress assembly can further include a fabric covering 206 encasing the first and second polymeric foam layers 202, 204. Each of the first and second polymeric foam layers has an outwardly facing planar top surface adapted to substantially face the user resting on the mattress assembly, depending on the orientation of the mattress assembly, and have length and width dimensions sufficient to support a reclining body of the user.

The first and second polymeric foam layer 202, 204 can have different thicknesses relative to one another. The exemplary compressible mattress assembly is typically less than 12 inches in height when decompressed, although greater thicknesses can be used.

By way of example, the first and second polymeric foam layers can be formed of, but are not limited to, polyurethane foams, latex foams including natural, blended and synthetic latex foams: polystyrene foams, polyethylene foams, polypropylene foam, polyether-polyurethane foams, and the like Likewise, the foam can be selected to be viscoelastic or non-viscoelastic. Any of these foams may be open celled or closed cell or a hybrid structure of open cell and closed cell. Likewise, the foams can be reticulated, partially reticulated or non-reticulated foams. The term reticulation generally refers to removal of cell membranes to create an open cell structure that is open to air and moisture flow. Still further, the foams may be gel-infused in some embodiments and/or may include a phase change material and/or may include thermally conductive fillers. The different foam layers can be formed of the same material configured with different properties or configured with different materials Although not shown, the compressible mattress assembly can include microcoil layers.

As used herein, a microcoil is a spring or coil that has a smaller height and diameter than conventional innersprings used in mattresses such as that used in a coil innercore, which are typically greater than 6 inches in height. Suitable dimensions for each microcoil include, but are not limited to, a diameter and height of less than about 4 inches. In one or more embodiments, the diameter of less than about 3 inches and in still one or more other embodiments, a diameter of less than about 2 inches. In one or more embodiments, the height of less than about 3 inches and in still one or more other embodiments, a height of less than about 2 inches The microcoils can be pre-compressed or uncompressed within the pocket. In addition, the microcoil is generally constructed from a thinner or more flexible gauge of wire. In one or more embodiments, the gauge of the wire is greater than about 14 gauge.

In another embodiment, the gauge of the wire utilized in forming the microcoils is at least about 19 gauge. In one or more embodiments, each microcoil within the array can have a cylindrical shape with a generally circular cross section. In one or more other embodiments, each microcoil within the array can have other shapes including barrel shaped, hour-glass shaped or cone shaped and can have other cross-sectional shapes including oblong and rectangular

The microcoil array can be in the form of a grid including rows and columns of pocketed microcoils. The microcoil array, when present, as well as the first and second foam polymeric foam layers 202, 204 can be adhesively secured to one another. The microcoil construction, when present, can employ a stranded wire spring which is made of at least 2 wire strands that are twisted to form a multi-wire cord. The number of strands employed will vary according to the application and may vary based on the type of material used to form the strand

By way of example of a compressible mattress assembly construction including different materials, the first polymeric foam layer can be a latex foam and the second polymeric foam layer can be a polyurethane foam, or vice versa. In another example, the first polymeric foam layer can be a viscoelastic foam layer and the second polymeric foam layer can be a non-viscoelastic foam layer, and vice versa. The particular combinations are not intended to be limited and are generally defined by the desired comfort and feel desired by the end user.

By way of example of a compressible mattress assembly construction including different properties, the first and second polymeric foam layers can be selected to have different hardness and/or density properties. In one or more embodiments, the thinner layer has a firmness greater than the thicker layer. In other embodiments, the thicker layer has a firmness greater than the thinner layer. In this manner, one of the first and second polymeric foam layers can be configured to have a soft feel, i.e., a plush side, and the other layer a firmer feel, i.e., a firm side. The hardness of the layers generally have an indention load deflection (ILD) of 7 to 22 pounds force for viscoelastic foams and an ILD of 7 to 55 pounds force for non- viscoelastic foams. ILD can be measured in accordance with ASTM D 3575. The density of the layers can generally range from about 1 to 2.5 pounds per cubic foot for non-viscoelastic foams and 1.5 to 6 pounds per cubic foot for viscoelastic foams. In one or more embodiments, the plush side can have an ILD of 15 to 20 and the firm side is a non-viscoelastic foam having an ILD of 45 pounds force to 50 pounds force. In other embodiments, the plush side can have an ILD of 18 pounds force to 22 pounds force and the firm side is a non-viscoelastic foam having an ILD of 35 pounds force to 40 pounds force and in still other embodiments, the plush side can have an ILD of 20 pounds force to 26 pounds force and the firm side is a non-viscoelastic foam having an ILD of 30 pounds force to 35 pounds force.

The fabric covering 206 can be any desired sheet of material, such as cotton, linen, synthetic fibers or a mixture thereof. The fabric covering can be quilted or non-quilted. Additionally, the fabric covering 206 can include additional layers such as a flame-retardant layer and/or backing layers (not shown). The various layers can be fixedly attached to one another by stitching, an adhesive, or the like to define a panel, which can be removable or non-removable, or can be individual layers.

Advantageously, by including the humidifying agent within the protective plastic wrap with the compressed mattress assembly, when a consumer unpacks the compressed mattress from the protective plastic wrap and allows decompression, the mattress can fully recover to its original uncompressed state Moreover, the use of the humidifying agent permits the use of lower density and less expensive foams, and especially those foams and materials used in compressible mattress assemblies including side rail assemblies.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. A compressed mattress assembly package for a bed in a box application, comprises: a compressed mattress assembly; a humidifying agent; and a hermetically sealed protective wrap about the compressed mattress assembly and the humidifying agent, wherein the compressed mattress assembly has a first height when compressed and a second height when decompressed, wherein the second height is greater than the first height.
 2. The compressible mattress assembly of claim 1, wherein the compressed mattress assembly comprises one or more compressible foam layers.
 3. The compressible mattress assembly of claim 2, further comprising a compressible side rail assembly about at least a portion of a perimeter of the compressed mattress assembly.
 4. The compressible mattress assembly of claim 2, wherein the compressed mattress assembly comprises a microcoil layer.
 5. The compressible mattress assembly of claim 1, wherein the compressed mattress assembly within the hermetically sealed protective wrap is folded in half and rolled and adapted to be inserted into a box.
 6. The compressible mattress assembly of claim 1, wherein the humidifying agent comprises water.
 8. The compressible mattress assembly of claim 6, further comprising a substrate, wherein the water is infused within the substrate.
 9. The compressible mattress assembly of claim 6, wherein the humidifying agent is infused within a substrate or inserted within a container.
 10. A process for packaging a compressible mattress assembly for a bed in a box application, comprising: inserting an uncompressed compressible mattress assembly into an opening of a protective plastic wrap; compressing the compressible mattress assembly and evacuating excess air within the plastic protective wrap; introducing a humidifying agent with the compressible mattress assembly prior to inserting the uncompressed compressible mattress assembly or prior to compressing the compressible mattress assembly; hermtically sealing the opening in the protective plastic wrap to provide a compressed mattress assembly package.
 11. The process of claim 10 further comprising: folding the compressed mattress assembly package in half; rolling the folded compressed mattress assembly package to form a rolled compressed mattress assembly package; and inserting the rolled compressed mattress assembly package into a box.
 12. The process of claim 11, further comprising shipping the box including the rolled compressed mattress assembly to a consumer.
 13. The process of claim 10, wherein the humidifying agent comprises water.
 14. The process of claim 13, further comprising a substrate, wherein the water is infused within the substrate.
 15. The process of claim 13, wherein the humidifying agent is infused within a substrate or inserted within a container. 